Cumberland Evaporative Cooling System Owner's manual

PNEG-885

Evaporative Cooling System

Installation Manual

PNEG-885

Version: 10.0

Date: 09-10-20

2PNEG-885 Evaporative Cooling System

NOTE: To achieve maximum efficiency and performance while ensuring long life from your

Recirculating Cooling System, it is imperative that it be installed and maintained correctly.

Please read all instructions carefully before beginning installation.

Table of Contents

PNEG-885 Evaporative Cooling System 3

Contents

Chapter 1 Safety .....................................................................................................................................................4

Safety Guidelines ...................................................................................................................................4

Cautionary Symbols Definitions .............................................................................................................5

Safety Cautions ......................................................................................................................................6

Safety Sign-Off Sheet ............................................................................................................................8

Chapter 2 Introduction to Evaporative Cooling ..................................................................................................9

Dry Bulb Temperature ............................................................................................................................9

Wet Bulb Temperature ...........................................................................................................................9

Wet Bulb Depression .............................................................................................................................9

Evaporative Pad Cooling Efficiency .......................................................................................................9

Enthalpy .................................................................................................................................................9

Specific Volume .....................................................................................................................................9

Dew Point Temperature .........................................................................................................................9

Relative Humidity ...................................................................................................................................9

Chapter 3 Evaporative Cooling Theory and Benefits .......................................................................................10

Evaporative Cooling Theory .................................................................................................................10

Benefits ................................................................................................................................................10

Placing the Evaporative Cooling System .............................................................................................10

Chapter 4 Evaporative System Installation .......................................................................................................11

RCS Evaporative Cooling Rough Opening ..........................................................................................11

Closed Top Cover Assembly Installation .............................................................................................14

Open Top Cover Assembly Installation ................................................................................................17

Trough Assembly Installation ...............................................................................................................19

Jet Pump System .................................................................................................................................21

Installing the Supply Line and Spray Bar .............................................................................................24

End Panel Assembly Installation ..........................................................................................................25

Setting the Media Pad ..........................................................................................................................26

Installing the Reservoir Tank ................................................................................................................29

Installing the Vertical Piping Assembly ................................................................................................30

End Jet Pump System ..........................................................................................................................32

Center Jet Pump System .....................................................................................................................35

Installing the Float Valve Assembly .....................................................................................................38

Installing the Round Float Valve Assembly (Optional) .........................................................................39

Wiring the Re-Circulating Cooling System ...........................................................................................40

Chapter 5 Operation and Maintenance of the Re-Circulating Cooling System ..............................................41

Initial Start-Up New Media ...................................................................................................................41

Normal Operation .................................................................................................................................41

Annual Shut Down and Start-Up Process ............................................................................................42

Annual Start-Up ....................................................................................................................................42

Algae/Bacteria Control .........................................................................................................................42

Maintenance/Water Chemistry .............................................................................................................43

Re-Circulating Closed Top Cooling System (RCS-10)......................................................................... 44

Re-Circulating Stainless Steel Open Top (RCS-10-OT) ...................................................................... 45

Re-Circulating Aluminum Open Top (RCS-10-OTA) ............................................................................46

Chapter 6 Appendix-I: Pad Retainers .................................................................................................................47

Installation of Pad Retainers ................................................................................................................47

Chapter 7 Appendix-II: Offset Support Brackets ..............................................................................................48

RCS Evaporative Cooling Rough Opening ..........................................................................................48

Chapter 8 Appendix-III: Disassembling the Jet Pump .....................................................................................50

Disassembling the Jet Pump from the Motor .......................................................................................50

Chapter 9 Appendix-IV: MegaCool Pump Components ..................................................................................52

Chapter 10 Warranty ............................................................................................................................................53

4PNEG-885 Evaporative Cooling System

1. Safety

Safety Guidelines

Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is

written to help you understand safe operating procedures and problems that can be encountered by the

operator and other personnel when using this equipment. Read and save these instructions.

As owner or operator, you are responsible for understanding the requirements, hazards, and precautions

that exist and to inform others as required. Unqualified persons must stay out of the work area at all times.

Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in

SERIOUS INJURY or DEATH.

This equipment must be installed in accordance with the current installation codes and applicable

regulations, which must be carefully followed in all cases. Authorities having jurisdiction must be consulted

before installations are made.

When necessary, you must consider the installation location relative to electrical, fuel and water utilities.

Personnel operating or working around equipment must read this manual. This manual must be delivered

with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the

equipment.

ST-0001-4

1. Safety

PNEG-885 Evaporative Cooling System 5

Cautionary Symbols Definitions

Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential

safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we

use the symbols that are defined below.

DANGER

WARNING

CAUTION

NOTICE

This symbol indicates an imminently hazardous situation

which, if not avoided, will result in serious injury or death.

This symbol indicates a potentially hazardous situation

which, if not avoided, can result in serious injury or death.

This symbol indicates a potentially hazardous situation which,

if not avoided, can result in minor or moderate injury.

This symbol is used to address practices not related to

personal injury.

This symbol indicates a general hazard.

This symbol indicates a prohibited activity.

This symbol indicates a mandatory action.

ST-0005-2

1. Safety

6PNEG-885 Evaporative Cooling System

Safety Cautions

Use Personal Protective Equipment

Eye

Protection

Hearing

Protection

Hand

Protection

Head

Protection

Respiratory

Protection Foot

Protection

Fall

Protection

• Use appropriate personal protective equipment:

• Wear clothing appropriate to the job.

• Remove all jewelry.

• Tie long hair up and back.

ST-0004-1

Follow Safety Instructions

• Carefully read all safety messages in this manual and

safety signs on your machine. Keep signs in good

condition. Replace missing or damaged safety signs.

Be sure new equipment components and repair parts

include the current safety signs. Replacement safety

signs are available from the manufacturer.

• Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without

instruction.

• If you do not understand any part of this manual or

need assistance, contact your dealer.

ST-0002-1

1. Safety

PNEG-885 Evaporative Cooling System 7

Maintain Equipment and Work Area

• Understand service procedures before doing work. Keep area

clean and dry.

• Never service equipment while it is operating. Keep hands, feet,

and clothing away from moving parts.

• Keep your equipment in proper working condition. Replace worn

or broken parts immediately.

ST-0003-1

Sharp Edge Hazard

• This product has sharp edges, which can cause serious injury.

• To avoid injury, handle sharp edges with caution and always use

proper protective clothing and equipment.

ST-0036-2

Install and Operate Electrical Equipment Properly

• Electrical controls must be installed by a qualified electrician

and must meet the standards set by applicable local codes

(National Electrical Code for the US, Canadian Electric Code,

or EN60204 along with applicable European Directives

for Europe).

• Lock-out power source before making adjustments, cleaning,

or maintaining equipment.

• Make sure all equipment is properly grounded.

ST-0027-4

1. Safety

8PNEG-885 Evaporative Cooling System

Safety Sign-Off Sheet

Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety

instructions. This sign-off sheet is provided for your convenience and personal record keeping.

Date Employee Name Supervisor Name

ST-0007

PNEG-885 Evaporative Cooling System 9

2. Introduction to Evaporative Cooling

When non-saturated air comes in contact with free moisture and the two are thermally isolated from an

outside heat source, there is a transfer of mass and heat. Because the vapor pressure of the free water

surface is higher than that of the unsaturated air, water transfers in response to the differential. The

transfer involves a change of state from liquid to vapor, requiring heat of vaporization. The heat recovery

for this change of state comes from the sensible heat content of both the air and water, resulting in a drop

of temperature of both. As the temperature in the immediate vicinity of the interface drops and creates a

temperature differential within the air vapor mixture, a transfer of heat occurs as the whole system

changes to a thermodynamic balance. Since no outside heat is added during the process, total heat

content does not change. There is simply an adiabatic exchange of latent heat for sensible heat.

A change in environment results, however, from the change of the state of water and change in

temperature of the air vapor mixture.

Dry Bulb Temperature

Dry bulb temperature is measured by a mercury in glass thermometer properly shielded from radiation,

wiped dry and given sufficient time to reach a steady state reading.

Wet Bulb Temperature

Wet bulb temperature is a value indicated on an ordinary mercury glass thermometer, whose bulb is

covered by a wet wick and placed in a 1000 FPM moving stream of air.

Wet Bulb Depression

Wet bulb depression is the difference in degrees between dry bulb and wet bulb temperature.

Evaporative Pad Cooling Efficiency

Evaporative pad cooling efficiency is the percentage of wet bulb depression that the air is cooled as it

passes through the pad.

Enthalpy

Enthalpy is the internal energy content of an air-water-vapor mixture. The energy contained in the mixture

can be present both as sensible heat (indicated by dry bulb temperature) and latent heat of vaporization

(energy content of the water vapor).

Specific Volume

Specific volume is the cubic feet of the mixture per pound of dry air.

Dew Point Temperature

Dew point temperature is the temperature at which moisture will start to condense from the air.

Relative Humidity

Relative humidity is the ratio of the partial pressure of the water vapor in moist air to the vapor pressure.

The relationship for the relative humidity is expressed as a percent.

10 PNEG-885 Evaporative Cooling System

3. Evaporative Cooling Theory and Benefits

Evaporative Cooling Theory

Evaporative cooling works by evaporating water into the air. In order for water to evaporate, it must absorb

heat, which is supplied by the outside air brought into the house for ventilation. As hot outside air comes

in contact with the wet evaporative cooling pad, some of the heat is absorbed by water and the air

becomes cooler. The water does not increase in temperature during this process, but only changes in

state from a liquid to a vapor.

How well evaporative cooling works depends partly on the weather. The air temperature in the building

can only be theoretically lowered to the dew point temperature. The dew point temperature can be

measured when the air is completely saturated with water (when the relative humidity is 100 percent).

Generally, the difference between the air temperature and the dew point temperature is greatest during

the warmest hours of the day. Therefore, an evaporative cooling system is most effective during the

hottest hours of the day.

The theoretical efficiency of the system is limited by the dew point temperature. The actual air temperature

in the building cannot be cooled to dew point temperature. Using a properly maintained system, however,

the air temperature in the building can be reduced to within 3°F - 5°F of the dew point temperature.

Benefits

Livestock and poultry cannot adequately remove excess body heat through sweating. The main way

animals lose heat is by the atmosphere. However, when the air temperature approaches the body

temperature of the animal, it becomes difficult to reduce body temperature through heat loss to the

atmosphere. Therefore, external cooling must be provided.

Evaporative cooling is a very cost effective way of reducing heat stress incurred by warm summer

temperatures. By providing a comfortably cooled environment, animals and poultry can experience better

weight gain, better production and improved reproductive characteristics.

Placing the Evaporative Cooling System

Each building and system is a little different just as management styles differ. The system can be located

such that it will be more of an outside attachment to the building or may be incorporated into the building

structure so that it is considered inside. Some of this depends on whether it is preferred to service from

inside or outside. It may depend on environmental conditions, especially in the winter where the system

is subject to less harsh conditions if located between a curtain and the animals. A closed curtain will serve

to prevent blowing dust, debris, rain and ice from entering the system.

PNEG-885 Evaporative Cooling System 11

4. Evaporative System Installation

RCS Evaporative Cooling Rough Opening

Step 1 (Frame Opening Size)

Frame should be equal to length of pad.

Frame should be equal to height of pad LESS 1/2". (See Figure 4A.)

Step 2

Frame in opening with treated lumber as shown in Figure 4A. Place 2" x 4" studs at four feet (4') intervals.

(LUMBER NOT PROVIDED.)

Figure 4A

If using offset brackets, See Appendix-II: Offset

Support Brackets on Page 48 for steps 1-3.

4. Evaporative System Installation

12 PNEG-885 Evaporative Cooling System

Step 3

Place trough support bracket 7" down from bottom of frame-out opening. Note that this dimension is from

where the trough will be placed on bracket not from the top of the bracket. See Figure 4A on Page 11 and

Figure 4B. Attach brackets to footer every 42" for the entire length of the system using lag screws.

(LAG SCREWS NOT PROVIDED.)

Step 3B

NOTE: If trough is placed directly on a concrete pad, distance from concrete pad to bottom of the header

equals cooling pad height plus 6-1/2".

Figure 4B

4. Evaporative System Installation

PNEG-885 Evaporative Cooling System 13

Figure 4C Pad Installation End View Cross Section

4. Evaporative System Installation

14 PNEG-885 Evaporative Cooling System

Closed Top Cover Assembly Installation

Step 4

Check rough opening for specified distance from support brackets (1/2" less than pad height).

If using the open top system, proceed to Step 5A on Page 17.

Step 5

Place the top back cover mounting ledge under the 2" x 4" header as shown in Figure 4D. Attach

spray bar supports firmly into place at two feet (2') intervals using the #10 x 1-1/4" screws provided.

(See Figure 4D.)

Figure 4D

4. Evaporative System Installation

PNEG-885 Evaporative Cooling System 15

Closed Top Cover Assembly Installation (Continued)

Step 6

Measure from end of top back cover to each hole in the spray bar supports. Record these measurements

for Step 7. (See Figure 4E.)

Figure 4E

Step 7

Transfer the measurements from Step 6 onto the front face of the top front cover starting at the same end

as in Step 6. Use a pencil to mark where holes will be drilled. (See Figure 4F.)

Figure 4F

4. Evaporative System Installation

16 PNEG-885 Evaporative Cooling System

Closed Top Cover Assembly Installation (Continued)

Step 8

Place the galvanized hole template provided onto the ledge of the front top cover to ensure the hole will

be at the correct height to line up with the hole on the pipe support bracket. Place the template so the

center of the hole in the template is over the marks from Step 7 on Page 15. Mark the center of the hole

and drill a 3/8" hole through the top front cover only. Repeat for each pipe support bracket in the system.

NOTE: For safety, drilling should be done on a flat, level surface. (See Figure 4G and Figure 4H.)

Figure 4G Figure 4H

Step 9

Check fit using the thumb screw and washer assembly provided.

Remove top front cover until further instructions. (See Figure 4I.)

Figure 4I

4. Evaporative System Installation

PNEG-885 Evaporative Cooling System 17

Open Top Cover Assembly Installation

Step 5A

Place top back cover onto the 2" x 4" header as shown in Figure 4J. Measure 2-1/4" from top of the support

to bottom of frame opening, place a #10 x 1-1/4" SS screw (S-7419) in each end of the support to hold it

in place. (See Figure 4J and Figure 4K.)

Figure 4J Figure 4K

Step 6A

Place pipe support brackets (60-0437) (2 per 10' section) inside top back cover aligning brackets to holes

in top back cover. Use two (2) #10 x 1-1/4" SS screws (S-7419) and washers (S-8306) per bracket.

(See Figure 4L.)

Figure 4L

4. Evaporative System Installation

18 PNEG-885 Evaporative Cooling System

Step 7A

Place spray bar deflector, with short leg to the front, onto the top back cover. Place two (2) #10 x 1/2"

stainless steel self-drilling screws (S-8445) in the two (2) middle screw holes only. (See Figure 4M.)

Figure 4M

Step 8A

Install a spray bar deflector splice under the spray bar deflector at each 10' joint. Use two (2) #10 x 1/2"

stainless steel self-drilling screws (S-8445) at each splice. (See Figure 4N.)

At each end of the system, do not place splices on the spray bar deflectors.

Figure 4N

At this point, continue assembling 10' sections following Steps 5A-8A (Pages 17 and 18) until the

required length of system is obtained.

4. Evaporative System Installation

PNEG-885 Evaporative Cooling System 19

Step 9A: Open Top System

Continue with Steps 10-17 (Pages 19-28) to complete this part of the installation. After pad has been

installed, place pad retainer over pad and pipe support brackets.

1. Insert spray bar retainer (60-0438) through pipe support bracket as shown in Figure 4O.

2. Flip retainer up so the ends rest on top of pad retainer.

Figure 4O

Trough Assembly Installation

Step 10 (See Figure 4P.)

Place sections of the square trough onto the supporting trough support brackets.

Figure 4P

Complete Steps 10-17 (Pages 19-28) before this final step.

4. Evaporative System Installation

20 PNEG-885 Evaporative Cooling System

Step 11

Clean all PVC surfaces of trough, end cap and couplers to be joined with PVC cleaner.

Apply the PVC compound liberally to both the inside of the couplers and end caps and the surfaces of the

trough. Connect and allow to set up for at least 12 hours before adding water. (See Figure 4Q.)

Step 12: Trough Cover Placement

Measure distance between couplers and subtract 1/4". Cut cover to fit trough (cut square).

Place sections of the trough cover onto the trough. (See Figure 4R.)

Do not use PVC cement on trough and cover joint.

Figure 4Q

Figure 4R Figure 4S

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Cumberland Evaporative Cooling System Owner's manual

Cumberland Evaporative Cooling System Owner's manual

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